Environmental barrier coating

ABSTRACT

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and a network of gettering particles in the matrix phase. The gettering particles have an average maximum dimension between about 30 and 70 microns. The gettering particles have maximum dimensions that range from about 1 to 100 microns, and a dispersion of barium-magnesium alumino-silicate particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/785,012, filed Feb. 7, 2020; the disclosure of which is incorporatedby reference in its entirety herein.

BACKGROUND

A gas turbine engine typically includes a fan section, a compressorsection, a combustor section and a turbine section. Air entering thecompressor section is compressed and delivered into the combustionsection where it is mixed with fuel and ignited to generate ahigh-energy exhaust gas flow. The high-energy exhaust gas flow expandsthrough the turbine section to drive the compressor and the fan section.The compressor section typically includes low and high pressurecompressors, and the turbine section includes low and high pressureturbines.

This disclosure relates to composite articles, such as those used in gasturbine engines. Components, such as gas turbine engine components, maybe subjected to high temperatures, corrosive and oxidative conditions,and elevated stress levels. In order to improve the thermal and/oroxidative stability, the component may include a protective barriercoating.

SUMMARY

An article according to an exemplary embodiment of this disclosure,among other possible things includes a ceramic-based substrate and abarrier layer on the ceramic-based substrate. The barrier layer includesa matrix phase and a network of gettering particles in the matrix phase.The gettering particles have an average maximum dimension between about30 and 70 microns. The gettering particles have maximum dimensions thatrange from about 1 to 100 microns. The barrier layer also includes adispersion of diffusive particles in the matrix phase.

In a further example of the foregoing, the barrier layer includes, byvolume, 30-94% of the gettering particles.

In a further example of any of the foregoing, the barrier layerincludes, by volume, 60-90% of the gettering particles.

In a further example of any of the foregoing, the barrier layerincludes, by volume, 1-30% of the diffusive particles, 5-40% of thematrix of SiO2, and a balance of the gettering particles.

In a further example of any of the foregoing, the diffusive particleshave an average maximum dimension that is smaller than the averagemaximum dimension of the gettering particles.

In a further example of any of the foregoing, the gettering particleshave an average maximum dimension that is between about 40 and 60microns.

In a further example of any of the foregoing, the gettering particleshave dimensions between about 5-75 microns.

In a further example of any of the foregoing, the gettering particlesare spherical.

In a further example of any of the foregoing, the gettering particlesare reactive with respect to oxidant species.

In a further example of any of the foregoing, the gettering particlesinclude at least one of silicon oxycarbide (SiOC) particles, siliconcarbide (SiC) particles, silicon nitride (Si₃N₄), siliconoxycarbonitride (SiOCN) particles, silicon aluminum oxynitride (SiAlON)particles, and silicon boron oxycarbonitride (SiBOCN) particles.

In a further example of any of the foregoing, the diffusive particlesinclude at least one of barium magnesium aluminum silicate (BMAS),barium strontium aluminum silicate, magnesium silicate, alkaline earthaluminum silicate, yttrium aluminum silicate, ytterbium aluminumsilicate, and rare earth metal aluminum silicate particles.

In a further example of any of the foregoing, the article furthercomprises a distinct intermediate layer between the barrier layer andthe ceramic-based substrate, the distinct intermediate layer includingan intermediate layer matrix of SiO₂ and a dispersion of intermediatelayer gettering particles in the intermediate layer matrix.

In a further example of any of the foregoing, the gettering particlesare silicon oxycarbide particles that have a composition SiOxMzCy, whereM is at least one metal, x<2, y>0 and z<1 and x and z are non-zero.

In a further example of any of the foregoing, the article includes aceramic-based top coat on the barrier layer.

A composite material according to an exemplary embodiment of thisdisclosure, among other possible things includes a matrix of SiO2 and adispersion of silicon oxycarbide particles in the matrix. The siliconoxycarbide particles have Si, O, and C in a covalently bonded network.The silicon oxycarbide particles have an average maximum dimensionbetween about 30 and 70 microns. The silicon oxycarbide particles havemaximum dimensions that range from about 1 to 100 microns. The compositematerial also includes a dispersion of barium-magnesium alumino-silicateparticles in the matrix.

In a further example of the foregoing, the silicon oxycarbide particleshave an average maximum dimension that is between about 40 and 60microns.

In a further example of any of the foregoing, the silicon oxycarbideparticles are approximately spherical.

In a further example of any of the foregoing, the silicon oxycarbideparticles are reactive with respect to oxidant species.

A method of applying a barrier layer to a substrate according to anexemplary embodiment of this disclosure, among other possible thingsincludes mixing particles of barium-magnesium alumino-silicate,particles of SiO2, and particles of silicon oxycarbide in a carrierfluid to form a slurry. The silicon oxycarbide particles have an averagemaximum dimension between about 30 and 70 microns. The siliconoxycarbide particles have maximum dimensions that range from about 1 to100 microns. The method includes applying the slurry to a substrate,drying the slurry, and curing the slurry such that cross-linking occursin the composite material.

In a further example of the foregoing, the application is by spraying.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an example gas turbine engine.

FIG. 2 illustrates an example article having a barrier layer of acomposite material that includes barium-magnesium alumino-silicateparticles.

FIG. 3 illustrates a network of silicon oxycarbide.

FIG. 4 illustrates another example article having a barrier layer of acomposite material that includes barium-magnesium alumino-silicateparticles.

FIG. 5 illustrates another example article having a barrier layer of acomposite material that includes barium-magnesium alumino-silicateparticles.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates a gas turbine engine 20. The gasturbine engine 20 is disclosed herein as a two-spool turbofan thatgenerally incorporates a fan section 22, a compressor section 24, acombustor section 26 and a turbine section 28. The fan section 22 drivesair along a bypass flow path B in a bypass duct defined within a housing15 such as a fan case or nacelle, and also drives air along a core flowpath C for compression and communication into the combustor section 26then expansion through the turbine section 28. Although depicted as atwo-spool turbofan gas turbine engine in the disclosed non-limitingembodiment, it should be understood that the concepts described hereinare not limited to use with two-spool turbofans as the teachings may beapplied to other types of turbine engines including three-spoolarchitectures.

The exemplary engine 20 generally includes a low speed spool 30 and ahigh speed spool 32 mounted for rotation about an engine centrallongitudinal axis A relative to an engine static structure 36 viaseveral bearing systems 38. It should be understood that various bearingsystems 38 at various locations may alternatively or additionally beprovided, and the location of bearing systems 38 may be varied asappropriate to the application.

The low speed spool 30 generally includes an inner shaft 40 thatinterconnects, a first (or low) pressure compressor 44 and a first (orlow) pressure turbine 46. The inner shaft 40 is connected to the fan 42through a speed change mechanism, which in exemplary gas turbine engine20 is illustrated as a geared architecture 48 to drive a fan 42 at alower speed than the low speed spool 30. The high speed spool 32includes an outer shaft 50 that interconnects a second (or high)pressure compressor 52 and a second (or high) pressure turbine 54. Acombustor 56 is arranged in exemplary gas turbine 20 between the highpressure compressor 52 and the high pressure turbine 54. A mid-turbineframe 57 of the engine static structure 36 may be arranged generallybetween the high pressure turbine 54 and the low pressure turbine 46.The mid-turbine frame 57 further supports bearing systems 38 in theturbine section 28. The inner shaft 40 and the outer shaft 50 areconcentric and rotate via bearing systems 38 about the engine centrallongitudinal axis A which is collinear with their longitudinal axes.

The core airflow is compressed by the low pressure compressor 44 thenthe high pressure compressor 52, mixed and burned with fuel in thecombustor 56, then expanded through the high pressure turbine 54 and lowpressure turbine 46. The mid-turbine frame 57 includes airfoils 59 whichare in the core airflow path C. The turbines 46, 54 rotationally drivethe respective low speed spool 30 and high speed spool 32 in response tothe expansion. It will be appreciated that each of the positions of thefan section 22, compressor section 24, combustor section 26, turbinesection 28, and fan drive gear system 48 may be varied. For example,gear system 48 may be located aft of the low pressure compressor, or aftof the combustor section 26 or even aft of turbine section 28, and fan42 may be positioned forward or aft of the location of gear system 48.

The engine 20 in one example is a high-bypass geared aircraft engine. Ina further example, the engine 20 bypass ratio is greater than about six(6), with an example embodiment being greater than about ten (10), thegeared architecture 48 is an epicyclic gear train, such as a planetarygear system or other gear system, with a gear reduction ratio of greaterthan about 2.3 and the low pressure turbine 46 has a pressure ratio thatis greater than about five. In one disclosed embodiment, the engine 20bypass ratio is greater than about ten (10:1), the fan diameter issignificantly larger than that of the low pressure compressor 44, andthe low pressure turbine 46 has a pressure ratio that is greater thanabout five 5:1. Low pressure turbine 46 pressure ratio is pressuremeasured prior to inlet of low pressure turbine 46 as related to thepressure at the outlet of the low pressure turbine 46 prior to anexhaust nozzle. The geared architecture 48 may be an epicycle geartrain, such as a planetary gear system or other gear system, with a gearreduction ratio of greater than about 2.3:1 and less than about 5:1. Itshould be understood, however, that the above parameters are onlyexemplary of one embodiment of a geared architecture engine and that thepresent invention is applicable to other gas turbine engines includingdirect drive turbofans. A significant amount of thrust is provided bythe bypass flow B due to the high bypass ratio. The fan section 22 ofthe engine 20 is designed for a particular flight condition—typicallycruise at about 0.8 Mach and about 35,000 feet (10,668 meters). Theflight condition of 0.8 Mach and 35,000 ft (10,668 meters), with theengine at its best fuel consumption—also known as “bucket cruise ThrustSpecific Fuel Consumption (‘TSFCT’)”—is the industry standard parameterof lbm of fuel being burned divided by lbf of thrust the engine producesat that minimum point. “Low fan pressure ratio” is the pressure ratioacross the fan blade alone, without a Fan Exit Guide Vane (“FEGV”)system. The low fan pressure ratio as disclosed herein according to onenon-limiting embodiment is less than about 1.45. “Low corrected fan tipspeed” is the actual fan tip speed in ft/sec divided by an industrystandard temperature correction of [(Tram ° R)/(518.7 ° R)]0.5. The “Lowcorrected fan tip speed” as disclosed herein according to onenon-limiting embodiment is less than about 1150 ft/second (350.5meters/second).

The example gas turbine engine includes the fan section 22 thatcomprises in one non-limiting embodiment less than about 26 fan blades.In another non-limiting embodiment, the fan section 22 includes lessthan about 20 fan blades. Moreover, in one disclosed embodiment the lowpressure turbine 46 includes no more than about 6 turbine rotors. Inanother non-limiting example embodiment the low pressure turbine 46includes about 3 turbine rotors. A ratio between the number of fanblades and the number of low pressure turbine rotors is between about3.3 and about 8.6. The example low pressure turbine 46 provides thedriving power to rotate the fan section 22 and therefore therelationship between the number of turbine rotors in the low pressureturbine 46 and the number of blades in the fan section 22 disclose anexample gas turbine engine 20 with increased power transfer efficiency.

FIG. 2 schematically illustrates a representative portion of an examplearticle 100 for the gas turbine engine 20 that includes a compositematerial 102 that is used as a barrier layer. The article 100 can be,for example, an airfoil in the compressor section 24 or turbine section28, a combustor liner panel in the combustor section 26, a blade outerair seal, or other component that would benefit from the examplesherein. In this example, the composite material 102 is used as anenvironmental barrier layer to protect an underlying substrate 104 fromenvironmental conditions, as well as thermal conditions. As will beappreciated, the composite material 102 can be used as a stand-alonebarrier layer, as an outermost/top coat with additional underlyinglayers, or in combination with other coating under- or over-layers, suchas, but not limited to, ceramic-based topcoats.

The composite material 102 includes a matrix of silicon dioxide (SiO₂)106, a dispersion of “gettering” particles, and a dispersion ofdiffusive particles. In one example, the gettering particles are siliconoxycarbide particles (SiOC) 108 and the diffusive particles arebarium-magnesium alumino-silicate particles 110 (“BMAS particles”),though other examples are contemplated. The gettering particles 108could be, for instance, silicon oxycarbide (SiOC) particles, siliconcarbide (SiC) particles, silicon nitride (Si₃N₄) particles, siliconoxycarbonitride (SiOCN) particles, silicon aluminum oxynitride (SiAlON)particles, silicon boron oxycarbonitride (SiBOCN) particles, orcombinations thereof. The diffusive particles 110 could be, forinstance, BMAS particles, barium strontium aluminum silicate particles,magnesium silicate particles, alkaline earth aluminum silicateparticles, yttrium aluminum silicate particles, ytterbium aluminumsilicate particles, other rare earth metal aluminum silicate particles,or combinations thereof.

The gettering particles 108 form a network within the matrix. Forinstance, silicon oxycarbide particles 108 have silicon, oxygen, andcarbon in a covalently bonded network, as shown in the example network112 in FIG. 3 .

The network 112 is amorphous and thus does not have long rangecrystalline structure. The illustrated network 112 is merely one examplein which at least a portion of the silicon atoms are bonded to both Oatoms and C atoms. As can be appreciated, the bonding of the network 112will vary depending upon the atomic ratios of the Si, C, and O. In oneexample, the silicon oxycarbide particles 108 have a compositionSiO_(x)M_(z)C_(y), where M is at least one metal, x<2, y>0, z<1, and xand z are non-zero. The metal can include aluminum, boron, transitionmetals, refractory metals, rare earth metals, alkaline earth metals orcombinations thereof.

In one example, the composite material 102 includes, by volume, 1-30% ofthe diffusive/BMAS particles 110. In a more particular example, thecomposite material 102 includes, by volume, 1-10% of diffusiveparticles. In a further example, the composite material 102 includes, byvolume, 30-94% of the gettering particles 108. In a particular example,the composite material includes, by volume, 60-90% of thegettering/particles 108. In one further example, the composite material102 includes, by volume, 5-40% of the matrix 26 of silicon dioxide. In afurther example, the composite material 102 includes, by volume, 1-30%of the diffusive particles 110, 5-40% of the matrix 106 of silicondioxide, and a balance of the gettering particles 108.

The barrier layer protects the underlying substrate 104 from oxygen andmoisture. For example, the substrate 104 can be a ceramic-basedsubstrate, such as a silicon-containing ceramic material. One example issilicon carbide. Another non-limiting example is silicon carbide fibersin a silicon carbide matrix. The gettering particles 108 and thediffusive particles 110 of the barrier layer function as an oxygen andmoisture diffusion barrier to limit the exposure of the underlyingsubstrate 104 to oxygen and/or moisture from the surroundingenvironment. Without being bound by any particular theory, the diffusiveparticles 110, such as BMAS particles 110, enhance oxidation andmoisture protection by diffusing to the outer surface of the barrierlayer opposite of the substrate 104 and forming a sealing layer thatseals the underlying substrate 104 from oxygen/moisture exposure.Additionally, cationic metal species of the diffusive particles 110 (forinstance, for BMAS particles, barium, magnesium, and aluminum) candiffuse into the gettering particles 108 to enhance oxidation stabilityof the gettering material. Further, the diffusion behavior of thediffusive particles 110 may operate to seal any microcracks that couldform in the barrier layer. Sealing the micro-cracks could prevent oxygenfrom infiltrating the barrier layer, which further enhances theoxidation resistance of the barrier layer. The gettering particles, suchas the gettering particles 108, can react with oxidant species, such asoxygen or water that could diffuse into the barrier layer. In this way,the gettering particles could reduce the likelihood of those oxidantspecies reaching and oxidizing the substrate 104.

It has been discovered that the effectiveness of the gettering particles108, such as the silicon oxycarbide particles 108, in providingoxidation resistance is related to the surface area of the particles. Ingeneral, the greater the surface area of the particles 108, the morelikely the individual particles 108 will encounter and react withoxidant species. Further, such reaction causes a consumption of thegettering material and corresponding buildup of oxide scale on thesurface of the particles 108, reducing the effective surface area of theparticles 108. Thus, the greater the surface area of the particles 108,the more surface area available for reacting with oxidant species, whichreduces the likelihood that oxidant species will reach and oxidize thesubstrate 104. Accordingly, particles 108 with higher surface areagenerally improve the effectiveness and longevity of the oxidationresistance of the barrier layer. However, practical and processingconstraints limit the size of particles 108. If the particles 108 aretoo large, application of the barrier layer (especially by spraycoating, discussed in more detail below) becomes difficult. Also, if theparticles 108 are too large, the packing effectiveness of the particles108 relative to one another within the barrier layer is decreased,meaning in some areas there may be relatively large distances betweenadjacent particles 108. In those areas, there may be reduced localizedoxidation resistance.

The effective surface area of the particles 108 is related to thedimension of the particles 108 and their shape. In one example,effective surface area of the particles 108 can be determined bydetermining one or more dimensions 108 of the particles by any knownimaging technique and calculating the surface area of the particles 108according to known relationship between the dimensions and the shape.Furthermore, an average effective surface area of the particles 108within the barrier layer can be approximated based on an averagedimensions of the particles 108 with in the barrier layer.

In one example, the particles 108 are approximately spherical in shape,e.g., they have an aspect ratio that is close to one (1:1 ratio).However, other shapes, such as elongated shapes with aspect ratios lessthan one, are also contemplated.

The particles 108 can be defined by an average maximum dimension of theparticles 108. In the example where the particles 108 are approximatelyspherical, the average maximum dimension corresponds to the diameter ofthe particles 108, represented by D1 in FIG. 5 . In one example, theparticles 108 have an average maximum dimension of between about 30-70microns. Still, any given sample of particles 108 contains particles 108of different sizes. In a particular example, 65%±5% by volume of theparticles 108 have a maximum dimension D1 of between about 30-70microns. In one example, the modal particle (which is sometimes known asd50) has D1 of about 55 microns, and 10% of the volume of the particleshave D1 within about 5% of the modal particle D1 (i.e. D1 rangingbetween 52.25 and 57.75 microns) and 72% of the volume of the particleshaving D1 within 50% of the modal particle D1 (i.e. D1 ranging between27.5 and 82.5 microns). For instance, in one example, the particles 108have an average maximum dimension of between about 30-70 microns andindividual particles 108 have maximum dimensions that range from about1-100 microns. In another example, the particles 108 have an averagemaximum dimension of between about 40-60 microns. In a further example,the particles 108 have an average maximum dimension of between about40-60 microns and individual particles 108 have maximum dimensions thatrange from about 5-75 microns.

As discussed above, the average maximum dimension of the particles 108is related to the average effective surface area of the particles 108 inthe barrier layer. In turn, a total effective surface area for theparticles 108 in the barrier layer is related to the amount of particles108 in the barrier layer (e.g., vol % of particles 108 in the compositematerial 102) and the thickness of the barrier layer. Generally, themore particles 108 in the barrier layer (e.g., the higher the vol. % ofparticles 108 in the composite material 102, the thicker the barrierlayer, or both), the higher the total effective surface area for theparticles 108 in the barrier layer. For an example barrier layer, thetotal effective surface area for the particles 108 is between about12,000 and 564,000 cm² per centimeter of barrier layer thickness. In afurther example, the total effective surface area for the particles 108is between about 25,700 to 90,000 cm² per centimeter of barrier layerthickness. In a further example, the total effective surface area forthe particles 108 is between about 30,000 to 67,500 cm² per centimeterof barrier layer thickness. In one example, an average maximum dimensionof the BMAS particles 110 is less than the average maximum dimension ofthe silicon oxycarbide particles 108.

FIG. 4 shows another example article 200 that includes the compositematerial 102 as a barrier layer arranged on the substrate 104. In thisexample, the article 200 additionally includes a ceramic-based top coat114 interfaced with the barrier layer. As an example, the ceramic-basedtop coat 114 can include one or more layers of an oxide-based material.The oxide-based material can be, for instance, hafnium-based oxides,yttrium-based oxides (such as hafnia, hafnium silicate, yttriumsilicate, yttria stabilized zirconia or gadolinia stabilized zirconia),or combinations thereof, but is not limited to such oxides.

FIG. 5 illustrates another example article 300 that is somewhat similarto the article 200 shown in FIG. 4 but includes a distinct intermediatelayer 316 interposed between the barrier layer of the composite material102 and the substrate 104. In this example, the distinct intermediatelayer 316 includes an intermediate layer matrix 318 of silicon dioxideand a dispersion of intermediate layer silicon oxycarbide particles 320in the intermediate layer matrix 318. The intermediate layer siliconoxycarbide particles 320 are similar to the silicon oxycarbide particles108 in composition but, in this example, the intermediate layer siliconoxycarbide particles 320 have an average maximum dimension (D2) that isless than the average maximum dimension (D1) of the silicon oxycarbideparticles 108. The relatively small intermediate layer siliconoxycarbide particles 320 provide a relatively low roughness for enhancedbonding with the underlying substrate 104. The larger silicon oxycarbideparticles 108 of the barrier layer provide enhanced blocking ofoxygen/moisture diffusion. Thus, in combination, the barrier layer andintermediate layer 316 provide good adhesion and good oxidation/moistureresistance. In one further example, D1 is 44-75 micrometers and D2 is1-44 micrometers.

In one example, the intermediate layer 316 can include, by volume, 5-40%of the intermediate layer matrix 318 of silicon dioxide and a balance ofthe intermediate layer silicon oxycarbide particles 320. In furtherexamples, a portion of the BMAS particles 110 from the barrier layer canpenetrate or diffuse into the intermediate layer 316, during processing,during operation at high temperatures, or both. In a further example, aseal coat layer of SiO₂, with or without BMAS particles, can be providedbetween the barrier layer and the intermediate layer 316 to providedadhesion and additional sealing. In further examples of any of thecompositions disclosed herein, said compositions can include only thelisted constituents. Additionally, in any of the examples disclosedherein, the matrix 106 and 318 can be continuous. The two-layerstructure can also demonstrate good oxidation protection at 2000-2700°F. for 500 hours or longer as well as good adhesion with theceramic-based top coat 114.

The barrier layer and/or intermediate layer 316 can be fabricated usinga slurry coating method. The appropriate slurries can be prepared bymixing components, such as silicon oxycarbide, barium-magnesiumalumino-silicate, and powder of silicon dioxide or colloidal silica(Ludox) in a carrier fluid, such as water. The slurries can be mixed byagitation or ball milling and the resulting slurry can be painted,dipped, sprayed or otherwise deposited onto the underlying substrate104. The slurry can then be dried at room temperature or at an elevatedtemperature to remove the carrier fluid. In one example, the slurry isdried and cured at about 100-300° C. for about 5-60 minutes. During theheating, cross-linking of the colloidal silica occurs. The green coatingcan then be sintered at an elevated temperature in air for a selectedamount of time. In one example, the sintering includes heating at 1500°C. or greater in an air environment for at least 1 hour.

The composite material 102 can be prepared using a slurry coatingmethod. Slurries can be prepared by mixing components such as SiOC,BMAS, SiO₂ or Ludox (a source colloidal SiO₂) and water using agitationor ball milling. Various slurry coating methods such as painting,dipping and spraying can be used to coat ceramic matrix composite (CMC)substrates. Coatings formed from slurry are dried at room temperatureand cured at 300° C. for about 5-60 minutes. During the heating,cross-linking of the colloidal silica occurs. This coating process canbe repeated until all layers are coated. The bond coat is finallysintered at 1500° C. in air for at least 1 hour.

In one further example, a slurry of SiOC/SiO₂ 75/25 vol % was preparedby mixing appropriate amounts of SiOC and Ludox colloidal silica. Asmall amount of water was added to adjust the viscosity. The slurry wasfurther mixed by ball milling for at least 15 hours. A slurry ofSiOC/BMAS/SiO₂ 80/5/15 vol % was prepared likewise by mixing appropriateamounts of SiOC, BMAS and Ludox colloidal silica and ball milling formore than 15 hours.

An inner layer was applied on a cleaned CMC substrate 104 by painting.The coating was then dried at room temperature for about 5-60 minutesand heated in oven at between about 100-300° C. for about 5-60 minutes.During the heating, cross-linking of the colloidal silica occurs. Anouter layer was applied in the same fashion as the inner layer with theexception that the outer layer was applied with two passes. In betweenthe two passes, in one example, the specimen is submerged in Ludoxcolloidal silica solution, air dried at room temperature and heattreated at between about 100-300° C. for about 5-60 minutes to provide asilica sealing layer. After completion of the two layer bond coat, thespecimen was sintered at 1500° C. for at least 1 hour.

Although the different examples are illustrated as having specificcomponents, the examples of this disclosure are not limited to thoseparticular combinations. It is possible to use some of the components orfeatures from any of the embodiments in combination with features orcomponents from any of the other embodiments.

The foregoing description shall be interpreted as illustrative and notin any limiting sense. A worker of ordinary skill in the art wouldunderstand that certain modifications could come within the scope ofthis disclosure. For these reasons, the following claims should bestudied to determine the true scope and content of this disclosure.

What is claimed is:
 1. An article comprising: a ceramic-based substrate;and a barrier layer on the ceramic-based substrate, the barrier layerincluding: a matrix phase, a network of gettering particles in thematrix phase, wherein the gettering particles have an average maximumdimension between about 30 and 70 microns, wherein the getteringparticles have maximum dimensions that range from about 1 to 100microns, and a dispersion of diffusive particles in the matrix phase. 2.The article as recited in claim 1, wherein the barrier layer includes,by volume, 30-94% of the gettering particles.
 3. The article as recitedin claim 2, wherein the barrier layer includes, by volume, 60-90% of thegettering particles.
 4. The article as recited in claim 1, wherein thebarrier layer includes, by volume, 1-30% of the diffusive particles,5-40% of the matrix of SiO₂, and a balance of the gettering particles.5. The article as recited in claim 1, wherein the diffusive particleshave an average maximum dimension that is smaller than the averagemaximum dimension of the gettering particles.
 6. The article as recitedin claim 1, wherein the gettering particles have an average maximumdimension that is between about 40 and 60 microns.
 7. The article asrecited in claim 6, wherein the gettering particles have dimensionsbetween about 5-75 microns.
 8. The article as recited in claim 1,wherein the gettering particles are spherical.
 9. The article as recitedin claim 1, wherein the gettering particles are reactive with respect tooxidant species.
 10. The article as recited in claim 1, wherein thegettering particles include at least one of silicon oxycarbide (SiOC)particles, silicon carbide (SiC) particles, silicon nitride (Si₃N₄),silicon oxycarbonitride (SiOCN) particles, silicon aluminum oxynitride(SiAlON) particles, and silicon boron oxycarbonitride (SiBOCN)particles.
 11. The article as recited in claim 1, wherein the diffusiveparticles include at least one of barium magnesium aluminum silicate(BMAS), barium strontium aluminum silicate, magnesium silicate, alkalineearth aluminum silicate, yttrium aluminum silicate, ytterbium aluminumsilicate, and rare earth metal aluminum silicate particles.
 12. Thearticle as recited in claim 1, further comprising a distinctintermediate layer between the barrier layer and the ceramic-basedsubstrate, the distinct intermediate layer including an intermediatelayer matrix of SiO₂ and a dispersion of intermediate layer getteringparticles in the intermediate layer matrix.
 13. The article as recitedin claim 1, wherein the gettering particles are silicon oxycarbideparticles that have a composition SiO_(x)M_(z)C_(y), where M is at leastone metal, x<2, y>0 and z<1 and x and z are non-zero, and wherein thediffusive particles are barium magnesium aluminum silicate particles.14. The article as recited in claim 1, further comprising aceramic-based top coat on the barrier layer.
 15. A composite materialcomprising: a matrix of SiO₂; a dispersion of silicon oxycarbideparticles in the matrix, the silicon oxycarbide particles having Si, O,and C in a covalently bonded network, wherein the silicon oxycarbideparticles have an average maximum dimension between about 30 and 70microns, wherein the silicon oxycarbide particles have maximumdimensions that range from about 1 to 100 microns; and a dispersion ofbarium-magnesium alumino-silicate particles in the matrix.
 16. Thecomposite material as recited in claim 15, wherein the siliconoxycarbide particles have an average maximum dimension that is betweenabout 40 and 60 microns.
 17. The composite material as recited in claim15, wherein the silicon oxycarbide particles are approximatelyspherical.
 18. The composite material as recited in claim 15, whereinthe silicon oxycarbide particles are reactive with respect to oxidantspecies.
 19. A method of applying a barrier layer to a substrate,comprising: mixing particles of barium-magnesium alumino-silicate,particles of SiO₂, and particles of silicon oxycarbide in a carrierfluid to form a slurry, wherein the silicon oxycarbide particles have anaverage maximum dimension between about 30 and 70 microns, wherein thesilicon oxycarbide particles have maximum dimensions that range fromabout 1 to 100 microns; applying the slurry to a substrate; drying theslurry; and curing the slurry such that cross-linking occurs in thecomposite material.
 20. The method of claim 19, wherein the applying isby spraying.